3D-CFD Combustion Analysis and Simulation of
Diesel Engine Performance
Mr. Balasaheb Dahifale, Mr. Aniket Ingole, Mr. Anand Patil
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
INDEX
Background
Objective
Inputs for 3D-CFD combustion analysis
CFD Modelling Overview
Ricardo Two Zone flamelet Combustion model
Results
Conclusions
Acknowledgments
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
BACKGROUND
Diesel engine combustion performance (BMEP, Fuel efficiency and Power density) and
emissions is a complex phenomenon and influenced by large number of parameters
related to fuel injection system, fuel properties , engine breathing parameters.
It may observed that detailed investigation of flow, combustion and heat transfer
inside the combustion chamber and engine performance is one of the most challenging
problem and many of the characteristics of combustion are difficult to capture during
experimental testing unless advance high speed combustion photography techniques
are used.
All of these parameters required detailed investigation which necessitates use of
advance 3D-CFD methods and software's. Hence It was decided to establish correlation
between experimental engine performance and emission parameters and 3D-CFD
predictions.
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
OBJECTIVE
Validation of 3D-CFD Combustion process and predictions with experimental engine
test data. Specifically to validate experimental engine test data such as IMEP, BMEP,
POWER, BSFC, and NOx trend analysis.
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
INPUTS FOR 3D CFD ANALYSIS
Inputs
Engine Specifications
Combustion Geometry
Fuel Injection System Data
Inputs Taken From Test Data
5 mode test data with details like Power, Torque, Bsfc, NOx etc.
In-Cylinder pressure Vs. CA data at 100%, 75% ,50% 25% & 10% Load Points @1500
rpm
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
INPUTS FOR 3D CFD ANALYSIS
Inputs Data for 3D CFD simulation
Input data used for 3D-Combustion Simulation
Sr. No.
Parameter
Unit
Geometry
.STL
Engine Rated Speed
rpm
Bore
mm
Stroke
mm
Bumping Clearance
mm
Conrod Length
mm
7
8
9
Exhaust Valve Opening
Exhaust Valve Closing
Inlet Valve Opening
Deg
Deg
Deg
10
Inlet Valve Closing
Deg
11
Max valve Lift
mm
12
Rated Power
kW
13
Swirl Ratio
14
Nozzle Holes
No
15
Hole Dia.
mm
16
Spray cone angle
Deg
17
Injector Inclination w.r.t Vertical
Deg
18
Bumping Clearance
mm
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
INPUTS FOR 3D CFD ANALYSIS
Boundary Motions
Number
Name
Motion
1
2
3
4
5
Ex_Valve
In_Valve
Bowl
Liner
Flame Face
Stationary
Stationary
Piston
Interpolated Displacement
Stationary
Inputs Taken from Test Data (5 Mode Test Data)
Sr. No.
Parameter
Unit
Injected Fuel Mass Flow Rate
Kg/hr
Injected Fuel Mass Flow Rate
Kg/sec
Injection Start Time(Dynamic)
bTDC
Injection Duration
CA
Fuel Density
Kg/m3
Static Injection Timing
bTDC
Fueling
mm3/stroke
Fueling
Kg/stroke
Mass per hole
kg
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
CFD MODELLING OVERVIEW
3D-CFD Bowl Mesh Model
Base Bowl 2D-Model
3D-CFD Mesh Model @ TDC
5/9/2015
3D-CFD Mesh Model @ BDC
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
RICARDO TWO - ZONE FLAMELET MODEL
The RTZF combustion model is based on a Two Zone assumptions.
1. Each computation cell is divided into burned and unburned zones
2. The burned zone is further divide into segregated and mixed zones
3. In mixed region air fuel is mixed and ready for chemical reactions
4. In non-premixed combustion fuel and air are in the segregated region
5. The mixed reactant to mixed region for combustion and finally in to burned zone
Reference-Vectis_2014.2_Manual
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
RESULTS-BASE COMBUSTION MODEL VALIDATION
Base combustion
model validated
satisfactorily
(within 3%) with
experimental
data
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
RESULTS-BASE COMBUSTION MODEL VALIDATION
5/9/2015
Base combustion model validated satisfactorily (within
3%) with experimental data for 25% load and 10 % load
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
RESULTS-BASE COMBUSTION MODEL VALIDATION
Base combustion model validated with
in 3% with experimental data for IMEP
at all load conditions.
The percentage difference between CFD
and Experimental data for BMEP at 25%
load was higher due to unavailability
exact of injection duration
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
RESULTS-BASE COMBUSTION MODEL VALIDATION
Base combustion model validated within
3% with experimental data for Power and
BSFC at 100%, 75%, 50%, and 25% load
conditions.
The percentage difference between CFD
and Experimental data for Power and BSFC
at 25% load was higher due to
unavailability of exact injection duration
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
RESULTS-BASE COMBUSTION MODEL VALIDATION
The three major mechanisms that describe the formation or NOx are:
Thermal or Zeldovich mechanism
Fenimore or prompt mechanism
N2O intermediate mechanism
Thermal or Zeldovich mechanism: describes NOx formation is highly
dependent on high temperature combustion system over a wide range of
equivalence ratios.
Fenimore or prompt : describes NOx formation in fuel rich combustion
systems.
The N2O intermediate mechanism: explains NOx formation in fuel lean,
low temperature combustion systems.
Reference - Periasamy, C. (2007), An Experimental and Numerical Study of
Evaporation Enhancement and Combustion in Porous Media. Doctoral
Dissertation, School of Aerospace and Mechanical Engineering, University of
Oklahoma, Norman, Oklahoma, USA.
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
RESULTS-BASE COMBUSTION MODEL VALIDATION
Fig shows temperature decreases
after combustion as gases expands
Fig shows that NOx emission
decreases with decease in
temperature. NOx is formed due to
local temperature peak at TDC
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
RESULTS-BASE COMBUSTION MODEL VALIDATION
Fig shows that the increase in CO2
percentage and decrease in oxygen
content with increase in load.
CFD results are in good agreement
(within 3%)with experimental data.
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
RESULTS-BASE COMBUSTION MODEL VALIDATION
Fig shows that the heat release started certain CA after TDC when
combustion take place.
CFD results are in good agreement with calculated total heat input
based on LHV and mass flow of fuel .
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
CONCLUSIONS
Calibration of 3D CFD combustion model validated satisfactorily for IMEP, BMEP,
POWER and BSFC at 100% , 75%, 50%, 25% and 10% load at 1500 rpm.
The NOx emission trend at 100% , 75%, 50%, 25% and 10% load and 1500 rpm was
in good agreement with the experimental NOx trend.
The average in cylinder temperature was increased with increase in percentage load
as expected.
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
FUTURE SCOPE
3D-CFD Combustion methodology will be used for engine performance
optimization
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
ACKNOWLEDGMENTS
TAFE Motors and Tractors Limited
Sanjeev Rajput
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
Mr. Balasaheb S. Dahifale
Deputy Manager
Centre of Excellence-Engines-TAFE Motors & Tractors Limited
Mechanical Engineer from P.E.S. Modern College of Engineering, Pune University
with Post Graduate specialization in Thermo-fluid Science from The University of
Oklahoma, USA & have been in CFD Research & Development field from last 4
years with total Experience of 6 years.
He had worked in various companies both Multi-National & Indian, such as KohlerLombardini and F1 Systems .
His major experience is in the area of CFD Flow, combustion and Conjugate heat
Transfer Analysis, Simulation & Development.
5/9/2015
Balasaheb Dahifale
Centre of Excellence (Engines) - TAFE Motors and Tractors Limited
